Concentric multi-pair cable with filler

Abstract

A cable including a first group of inner twisted conductor pairs and a second group of outer twisted conductor pairs. The first group of inner pairs is twisted at a first twist rate, the second group of outer pairs is twisted at a second twist rate.

1. A cable, comprising:
 a) a first grouping of twisted conductor pairs, the first grouping of twisted conductor pairs including twisted conductor pairs each having different individual twist rates, each of the twisted conductor pairs being twisted in the same direction, the direction being only one of a right-handed twist direction and a left-handed twist direction, the first grouping defining an inner core, the inner core being twisted at a first twist rate, the inner core being twisted in the same direction as the twisted conductor pairs; and 
 b) a second grouping of twisted conductor pairs, the second grouping defining an outer layer of twisted conductor pairs that surrounds the inner core, the outer layer being twisted at a second twist rate, the second twist rate of the outer layer being different than the first twist rate of the inner core, the outer layer being twisted in the same direction as the inner core. 
 
   
   
     2. The cable of  claim 1 , wherein the first grouping of twisted conductor pairs includes four twisted conductor pairs. 
   
   
     3. The cable of  claim 1 , wherein the second grouping of twisted conductor pairs includes twisted conductor pairs having individual twist rates, the individual twist rates of each of the twisted conductor pairs of the second grouping being greater than the different individual twist rates of each of the twisted conductor pairs of the first grouping. 
   
   
     4. The cable of  claim 3 , wherein each of the twisted conductor pairs of the second grouping are individually twisted in the same direction, the direction being only one of a right-handed twist direction and a left-banded twist direction. 
   
   
     5. The cable of  claim 3 , wherein each of the individual twist rates of the twisted conductor pairs of the second grouping is between about 12.4 twists per linear foot and 27.0 twists per linear foot. 
   
   
     6. The cable of  claim 1 , wherein the second grouping of twisted conductor pairs includes twelve twisted conductor pairs. 
   
   
     7. The cable of  claim 6 , wherein each one of the twelve twisted conductor pairs of the second grouping has one of four different twist rates. 
   
   
     8. The cable of  claim 1 , wherein the second grouping of twisted conductor pairs includes twisted conductor pairs having different individual twist rates than other twisted conductor pairs of the second grouping. 
   
   
     9. The cable of  claim 1 , wherein the inner core further includes a filler, the twisted conductor pairs of the first grouping being positioned within pockets defined by the filler. 
   
   
     10. The cable of  claim 1 , further including a jacket that covers the first and second groupings of twisted conductor pairs. 
   
   
     11. The cable of  claim 10 , wherein the jacket includes a metal layer for shielding the cable from interference that can affect signal transmissions through the cable. 
   
   
     12. The cable of  claim 11 , wherein the jacket includes an inner jacket layer and an outer jacket layer, the metal layer being positioned between the inner jacket layer and the outer jacket layer. 
   
   
     13. The cable of  claim 1 , wherein the second grouping of twisted conductor pairs are spaced at approximately equal intervals about a circumference of the inner core. 
   
   
     14. The cable of  claim 1 , wherein each of the different individual twist rates of the twisted conductor pairs of the first grouping is between about 27.3 twists per linear foot and 36.8 twists per linear foot. 
   
   
     15. The cable of  claim 1 , wherein the first twist rate of the inner core is approximately 4.8 twists per linear foot. 
   
   
     16. The cable of  claim 1 , wherein the second twist rate of the outer layer is approximately 1.3 twists per linear foot. 
   
   
     17. A cable, comprising:
 a) a filler defining a number of pockets; 
 b) a plurality of inner twisted conductor pairs, each one of the inner twisted conductor pairs being positioned within one of the number of pockets defined by the filler, the filler and the plurality of inner twisted conductor pairs defining a twisted core having a first twist rate; and 
 c) an outer layer of twisted conductor pairs positioned about the twisted core, the outer layer of twisted conductor pairs having a second twist rate, the second twist rate of the outer layer being different than, and in the same direction as, the first twist rate of the twisted core. 
 
   
   
     18. The cable of  claim 17 , wherein the filler includes radial extensions that define the number of pockets. 
   
   
     19. The cable of  claim 18 , wherein the filler includes retaining members located at free ends of the radial extensions, the retaining members being arranged to retain the inner twisted conductor pairs within the pockets of the filler. 
   
   
     20. The cable of  claim 19 , wherein the retaining members have a length transverse to a length of the radial extensions. 
   
   
     21. The cable of  claim 17 , wherein each of the inner twisted conductor pairs has a different individual twist rate than the other inner twisted conductor pairs. 
   
   
     22. The cable of  claim 21 , wherein the different individual twist rates of each of the inner twisted conductor pairs defines a range of twist rates, and wherein the outer twisted conductor pairs of the outer layer each have an individual twist rate, the individual twist rates of the outer twisted conductor pairs being outside the range of twist rates of the inner twisted conductor pairs. 
   
   
     23. The cable of  claim 21 , wherein the different individual twist rates of the inner twisted conductor pairs have the same twist direction, the direction being only one of a right-handed twist direction and a left-handed twist direction. 
   
   
     24. The cable of  claim 23 , wherein the first twist rate of the twisted core has the same twist direction as the inner twisted conductor pairs. 
   
   
     25. The cable of  claim 21 , wherein the different individual twist rates of the inner twisted conductor pairs are between about 27.3 twists per linear foot and 36.8 twists per linear foot. 
   
   
     26. The cable of  claim 17 , wherein each of the twisted conductor pairs of the outer layer has an individual twist rate, the individual twist rates being between about 12.4 twists per linear foot and 27.0 twists per linear foot. 
   
   
     27. The cable of  claim 17 , wherein each of the twisted conductor pairs of the outer layer are individually twisted in the same direction, the direction being only one of a right-handed twist direction and a left-handed twist direction. 
   
   
     28. The cable of  claim 17 , wherein the first twist rate of the twisted core is approximately 4.8 twists per linear foot. 
   
   
     29. The cable of  claim 17 , wherein the second twist rate of the outer layer is approximately 1.3 twists per linear foot. 
   
   
     30. A method of manufacturing a cable, the method including the steps of:
 a) positioning each one of a plurality of inner twisted conductor pairs within a pocket of a filler, the positioned inner twisted conductor pairs and the filler defining an inner core having a circumference; 
 b) twisting the inner core at an initial twist rate and in a first direction; 
 c) positioning a number of outer twisted conductor pairs about the circumference of the inner core; and 
 d) twisting the inner core and the outer twisted conductor pairs at a second twist rate, and in the first direction. 
 
   
   
     31. The method of  claim 30 , further including individually twisting each of the inner twisted conductor pairs in a twist direction, the direction being only one of a right-handed twist direction and a left-handed twist direction. 
   
   
     32. The method of  claim 31 , further including twisting each of the inner twisted conductor pairs at a different individual twist rate. 
   
   
     33. The method of  claim 32 , wherein the step of twisting each of the inner twisted conductor pairs includes twisting each of the inner twisted conductor pairs at a rate of between about 27.3 twists per linear foot and 36.8 twists per linear foot. 
   
   
     34. The method of  claim 30 , further including individually twisting each of the outer twisted conductor pairs in a twist direction, the direction being only one of a right-handed twist direction and a left-handed twist direction. 
   
   
     35. The method of  claim 34 , further including twisting each of the outer twisted conductor pairs at an individual twist rate, the individual twist rates being between about 12.4 twists per linear foot and 27.0 twists per linear foot. 
   
   
     36. The method of  claim 30 , wherein the step of twisting the inner core at an initial twist rate includes twisting the inner core at an initial twist rate of approximately 4 twists per linear foot. 
   
   
     37. The method of  claim 36 , wherein the step of twisting the inner core and the outer twisted conductor pairs includes twisting the inner core and the outer twisted conductor pairs at a second twist rate of approximately 1.3 twists per linear foot.